Method for producing a polymer

ABSTRACT

The present invention relates to a method for performing a polymerization process in a stirred reactor, wherein a critical time window is determined by means of a monitor of at least one polymerization process parameter and an associated process window, and when a critical time window is present, an adaptation of process conditions is made in order to configure the polymerization process to conform to the process window.

This application is a U.S. national stage application claiming thebenefit of International Application No. PCT/EP2008/007317 filed Sep. 8,2008, which claims benefit of European Patent No. 07024978.4 filed Dec.21, 2007.

The present invention relates to a method for producing a polymer.

The classical parameters which are relevant when setting up apolymerization process are the composition of the polymer, the reactiontemperature, the viscosity, the reaction pressure, concentration ratiosof the reactants, the pH in the case of aqueous systems, the molecularweight distribution and the particle size of a heterophase polymer.Other process-relevant quantities derivable from the process are theheat transfer coefficient, the mixing time, the degree of dispersing,shear load and maximum shear stress and the power input. It should beunderstood here that the first-mentioned parameters rather characterizethe polymeric product while the process-relevant quantities on the otherhand describe and characterize the process and the process control.Reliable process control, in particular in relatively large reactioncontainers, ensures that the reaction product is obtained exactly withsaid and required product properties.

EP 1 163 504 B1 discloses a method for producing latex by emulsionpolymerization, the online monitoring/control being effected by means ofRaman spectroscopy. The data obtained on the basis of the Raman spectraare compared with specific reference data and, starting from thiscomparison, the reaction parameters are controlled so that a deviationof the measured data from the reference data is minimized. Inparticular, temperature, pressure, movement of the medium and meteringof the monomer are mentioned as reaction parameters.

U.S. Pat. No. 6,657,019 B2 discloses a method for predicting polymerlatex properties in a polymerization method, in which a set ofparameters of the method is measured and is evaluated on the basis ofheat and mass balance and the data obtained are compared with a set ofpredetermined data and statistical relationships between the parametersof the method in order thus to predict the properties of the polymer.

U.S. Pat. No. 6,991,763 B2 discloses a method for controlling themonomer level in a polymerization reaction. This method is based on acalorimetric measurement in which the cooling medium temperature at theentrance of the cooling jacket and at the exit of the cooling jacket andthe flow rate of the cooling medium are measured. The heat transfer isdetermined from these values and is compared with a target value for theheat output. Starting from this, the monomer feed is regulated.

Waβmer et al., in “A Unified Model for the Mixing of Non-NewtonianFluids in the Laminar, Transition and Turbulent Region”, Macromol.Mater. Eng. 2005, 290, 294-301, are concerned with the power inputcalculation in the case of structurally viscous systems comprisingfluids for which a Reynolds number cannot be calculated directly. It isfound that the fluid behavior of non-Newtonian fluids has a considerableinfluence on the calculation of process-relevant parameters, inparticular power input, mixing time and heat transfer. A relationshipbetween shear stress and specific power input is described. Furthermore,it is stated that the effective shear rate in the transition regionbetween laminar and turbulent in a vessel and the stirrer speed are notlinearly dependent.

U.S. Pat. No. 4,833,180 discloses a method for producing polyvinylchloride, in which the polymerization process is adjusted so that acertain shear rate (between a paddle stirrer and a deflector) isachieved. A relationship between shear rates and coagulum formation orvariation of the shear rates for avoiding coagulum formation is notdiscussed.

K. Takahashi et al., in “Mixing performance experiments in impellerstirred tanks subjected to unsteady rotational speeds”, Chem.Engineering Science, Vol. 53, No. 17, p. 3031-3040 (1998), show theinfluence of different stirring profiles on the speed of adecolorization reaction in a highly viscous, homogeneous polymersolution. From the results, it is concluded that the increase in theturbulence of the liquid phase due to the non-stationary stirringconditions leads to an improvement in the mixing effect. The methodpresented comprises a decolorization reaction in a transparent solutionwhich permits the required changes in the stirring conditions withoutproblems. However, the discoveries cannot be applied to disperse systemswhich are not transparent, frequently have shear-dependent viscosityvalues and show shear-dependent coagulation.

It is an object of the invention to provide a method for producingpolymers, in which in particular the heat removal is optimized and inwhich no coagulation of the polymer particles produced occurs. Adeterioration in the product properties is to be avoided.

It has now been found that a process optimization can be effected bydetermining so-called critical time windows within which the processthreatens to become faulty, i.e. for example coagulum formation,increased foam formation or stirring of gas into the product begins.During such a critical time window, the process should be returned tothe corresponding process window or should be kept in said window in atargeted manner.

This can be achieved, for example, by influencing the flow behavior,which in turn can be effected in particular by varying the stirringspeed but also by varying other suitable parameters.

Preferred polymerization process parameters are the heat transfercoefficient, the reaction temperature, the reaction pressure, thespecific mixing time, the conversion in the reaction, the shear stress,the degree of dispersing or the specific power input. The chemicalcomposition of the polymer should not be changed.

Suitable parameters to be adapted are the heat transfer coefficient, themixing time, the conversion in the reaction, the shear stress or thespecific power input. The shear stress is preferred since it can beeasily determined and can be changed by changing the stirrer speed andis frequently responsible for the formation of undesired byproducts. Thedetermination of the shear stress can be effected by empirical methods(trial and error), via a shear stress measurement or viscositymeasurement (i.e. using a reaction viscometer) or by means of arheometric cell.

Process window is understood as meaning the possible range of allprocess parameters as a function of the reaction time in which areaction product is obtained which meets the requirements. Therequirements are defined by the corresponding performancecharacteristics of the product.

For the respective polymerization process, the sensitivity of thereaction with respect to the selected parameter must first bedetermined. This is effected by determining the process window of theselected parameter. For this purpose, the limits within which theselected parameters can be varied in the process under consideration aredetermined, for example in preparatory laboratory experiments. Thecritical time window for the selected parameter is then determined. Thiscan be done online or offline and can be effected on the laboratory,pilot or production scale.

In the case of the shear stress, this means, for example, determiningthe critical time window with the greatest sensitivity to shearingduring the course of the reaction. Preferably, the determination of thecritical time window is effected by comparison of a (measured) value forthe at least one polymerization process parameter (shear stress producedby increasing shearing of the product) within the coordinated processwindow during the reaction time. The greatest sensitivity to shearing ofthe product is then seen in the course of time in which the formation ofagglomerates or microcoagulum occurs and the measured quantity exceeds atolerance value. The tolerance value is obtained in a comparableexperiment in the non-optimized process window. The time window thusidentified is therefore critical for this process parameter if itdeviates from the acceptable value of the measured quantity in saidwindow.

In a preferred embodiment of the invention, the coordinated processwindow is subject to a time change.

The invention relates to methods for determining a critical time windowin a polymerization process which is carried out in a stirred reactor.

In an embodiment, the invention comprises a method for determining atime window in a heterophase polymerization, in which microcoagulum isformed, by continuous removal of a portion of the reaction mixture fromthe reaction container and pumped circulation and optionally recyclingof the portion into the reaction container via a bypass which comprisesa measuring arrangement which measures the increase in a particle size,the time window being present when the measured particle size is atleast 1.5 times the expected statistical mean value of the end product.

The increase in the particle size is determined by monitoring theparticle size. Use is made of the fact that the number of particles isconstant during the polymerization, i.e. only the size of the particlesincreases during the reaction. By continuous repetition of themeasurement, the increase in the particle size is detected thereby.

In a further embodiment, the invention comprises a method fordetermining a time window in which micro-coagulum and/or shear coagulumis produced by shear load in a polymerization process, by continuousremoval of a portion of the reaction mixture from the reaction containerand pumped circulation and optionally recycling of the portion into thereaction container via a bypass in which a high-speed stirrer produces ashear field in the product flowing around, and optionally induces theincrease of the size of the polymer particles thereby, and subsequentdetection of the polymer particles by filtration and/or optical and/orelectrical detection.

In a further embodiment, the invention comprises a method fordetermining a time window in which mixing processes which optionallychange in a disadvantageous manner (such as, for example, insufficientor excessively slow mixing in of reactants and/or micro-coagulumformation) as a result of the progress of the reaction and/or as aresult of a change in the process parameters occur during thepreparation process, the time window being determined by adding asuitable tracer to the reaction mixture and monitoring thehomogenization of the reaction mixture by means of a suitablespectroscopic or electrochemical method in the container or in a bypassline. The critical time window is detected here by comparison of asuitable measured variable against the variation of its value in acomparative experiment in the non-optimized process window. For example,it is known that vinyl ester monomers undergo hydrolysis at unfavorablepH. The hydrolysis is a reaction which competes for the polymerizationand leads to nonpolymeric byproducts which occur in the end product andpresent problems. In the case of insufficient mixing in andhomogenization in a production container in the process window with ahigher reaction temperature and non-neutral pH conditions, the level ofbyproducts increases.

The invention also relates to apparatuses for determining a criticaltime window in a polymerization process which is carried out in astirred reactor.

The apparatuses according to the invention comprise means for removing aportion of the reaction mixture from the reaction container, means forpumping the portion of the reaction mixture and optionally means forrecycling the portion of the reaction mixture into the reactioncontainer, and means for measuring a physical property of the portion ofthe reaction mixture.

In an embodiment, the physical property to be measured is the particlesize of polymer particles which are suspended in the portion of thereaction mixture. In another embodiment, the physical property to bemeasured is the distribution of a tracer in the portion of the reactionmixture. In a further embodiment, the physical property to be measuredis the viscosity of the portion of the reaction mixture.

In a preferred embodiment, the apparatus according to the invention alsocomprises a container through which the portion of the reaction mixtureis pumped, a high-speed stirrer which produces a shear field in thereaction mixture flowing around, and means for filtration and/or opticaland/or electrical detection of polymer particles, being arranged in thecontainer.

The invention furthermore relates to a method for carrying out apolymerization process in a stirred reactor, in which a critical timewindow in the process window (optionally changing as a function of time)is determined by means of monitoring at least one polymerization processparameter and a coordinated process window and, if a critical timewindow is present, optionally an adaptation of process conditions iscarried out in order to configure the polymerization process to conformto the process window, i.e. to keep the process in the process window orto return the process to said window. At least one process parameter isactively adjusted to a new value which is advantageous for the processand/or the product, i.e. the process properties or product propertiesshould not deteriorate. Conforming to the process window is not to beunderstood in such a way that a parameter, once chosen, is to be kept atits required value. Rather, a new value is chosen in a targeted mannerso that the process remains within the variation of the prescribedprocess quantities as a function of time, i.e. follows the chronologicalspecification, including possible changes in the required value oftemperature, pressure, metering rates, stirrer speed, pH, etc. duringthe polymerization reaction.

In a preferred embodiment of the invention, the coordinated processwindow is subject to a change as a function of time. In a furtherpreferred embodiment of the invention, the adaptation of the processconditions is effected by influencing the flow behavior.

It has been found that, for optimizing the polymerization process, it isoften sufficient to adapt the shear stress only within the critical timewindow. This is the case in particular when opposing effects areproduced by changing the parameter. An increase in the shear stress viathe increase in the stirrer speed leads firstly to an improvement in theheat transfer, which permits more intensive cooling and thereby fastermetering of the reactants; secondly, the specific power input isincreased thereby and the stability of the product to shearing ispossibly exceeded, with the result that the product quality may beadversely affected by formation of fine coagulum (specks). Likewise, onincreasing the stirrer speed, the danger of shearing-induced coagulumformation in the product and on the stirrer surfaces and other containersurfaces and increased foam formation on the product surface as well asintroduction of air or gas into the stirred product itself increases.

Frequently, the process window will change during the polymerizationprocess, corresponding to the various phases of the polymerization.Thus, during the metering phase of the process, the mixing of thecomponents is of primary importance, with the aim of as homogeneousmixing as possible within as short a time as possible. During thereaction of the monomers, the aim is to suppress the formation ofcoagula; as the reaction progresses, attention is focused on the heattransfer, owing to the increase in the viscosity of the reactionmixture, whereas the power input must be controlled in particular in thestage of particle formation. Accordingly, a plurality of critical timewindows may also occur during the polymerization process, which in eachcase are coordinated with a different phase of the reaction. It may alsobe appropriate to choose a different process parameter for each phase,for example the mixing time for the metering phase, the shear stress forthe phase of coagulum formation, the heat transfer coefficient for thephase of viscosity increase and the power input for the phase ofparticle formation. Depending on the system, the phases may also occursimultaneously or may overlap with respect to time. If no critical timewindow was detected, this means that the polymerization process is notcritical with respect to this process parameter in the limitsinvestigated and this can be further increased for optimization purposesuntil it becomes critical.

The adaptation of the process conditions in the presence of a criticaltime window in order to configure the polymerization process to conformto the process window, i.e. to keep the process parameter underconsideration within the process window or to return it there in theevent of a deviation, can be effected by influencing the flow behaviorof the reaction mixture, for example by variation (as a rule anincrease) of the stirrer speed. This may be linear as a step ornonlinear; it may also take place several times or be periodicallyincreased and decreased. A further possibility is to change (as a ruleincrease) the reaction temperature in order to reduce the viscosity ofthe product and to increase the reaction rate and the coolingperformance of the reactor.

The method according to the invention can be used in various types ofpolymerization processes, in particular mass, solution, emulsion andsuspension polymerization. In emulsion polymerization, which ispreferred in its semi-batch form, a lower pressure at the end of thereaction and faster metering of the monomers can also be achieved withconcomitant use of low-boiling monomers, in addition to reduction ofcoagulum formation and improvement of heat removal. In the case ofsuspension polymerization, the method according to the invention permitsnot only a shortening of the cycle time and of the pressure increase inthe method but also improved control of the particle size and particlesize distribution. In solution polymerization, particularly in the caseof very viscous products, improvements in the heat removal and in themixing in of the condensate returning from the evaporative cooling canbe achieved. This applies to a comparable extent also for emulsionpolymerization, mass polymerization and polyaddition andpolycondensation reactions. The polymerization can be initiated by meansof free radicals, cationically or anionically.

The method according to the invention can be used in a comparable manneralso in the case of polycondensation and polyaddition reactions in whichlow molecular weight building blocks are converted in solution or in theabsence of a solvent by chemical reactions into high molecular weightpolymers. In these processes, the process-relevant parameters, such asheat transfer coefficient, mixing time and power input, in exceptionalcases also shear stress when foaming systems are present, are alsomonitored in addition to the reaction parameters.

Polymerization reactions can be carried out or begun at low reactionpressure, e.g. reduced pressure, under air or under inert gas or can becarried out in the case of gaseous starting materials under highpressure up to 200 bar. Depending on the reactivity of the startingmaterials, reaction temperatures of from −40° C. to 180° C. are chosen,preferably from 10° C. to 150° C., very particularly preferably from 60°C. to 130° C.

A particular embodiment represents heterophase polymers in which thepolymer is present in a separate phase. This separate phase is finelydispersed in a solvent, as a rule water, and its proportion is usuallyfrom 30 to 70% by weight. The products may be present in monomodal,bimodal or polymodal form, i.e. have either uniform particle sizes orvery nonuniform particle sizes, which means that, for example, smallparticles are present in addition to large particles. The particle sizeis in the range from 30 nm to 1 μm, preferably in the range from 100 to600 nm. Typical pH values of the products are in the range from 3 to 9,and the dynamic viscosities are in the range from 0.01 to 2 Pa·s.Non-Newtonian rheology behavior also frequently occurs as a complicatingfactor in the case of such products. The auxiliaries concomitantly usedin the synthesis, the particle size distribution of the particles andthe intrinsic pH and the viscosity are usually specified and defined bythe technical field of use of the products. Preferably, the polymercomposition which has been found in a laboratory experiment and hasproven to be suitable for the application is retained if it is repeatedon the production scale, since frequently approvals are related to thepolymer compositions.

A preferred embodiment of the method according to the invention makesuse of free radical emulsion polymerization of unsaturated monomers.Such monomers are esters of acrylic and/or methacrylic acid with C1- toC12-alcohols in the side chain, styrene, acrylonitrile, acrylic and/ormethacrylic acid and/or amides thereof, vinyl acetate, butadiene, vinylchloride and/or vinylidene chloride. The monomers can be reacted aloneto give homopolymers or, in certain mixtures, lead to correspondingcopolymers. The reaction is usually initiated by means of diazocompounds or peroxides, such as hydrogen peroxide, alkali metalperoxodisulfates or hydroperoxides, if necessary in combination withreducing agents and polyvalent metal salts. Crosslinking agents,chain-transfer agents and emulsifiers and further assistants, such asneutralizing agents and preservatives, can be mentioned as further,important additives, the use and deployment of which are sufficientlywell known to a person skilled in the art from the prior art. The usethereof leads to suitable polymer properties and product qualities.

Below, the process parameters which can be utilized in the methodaccording to the invention are described:

In the case of aqueous systems of heterophase polymers, in particular pHand electrolyte stability of the colloidal systems play a decisive role,in particular in the initial phase of the polymerization reaction. Thesequantities can be quantitatively determined and monitored by a pH probeor a conductivity-measuring probe in the polymerization container.

The monitoring of the conversion of the reaction is to be determinedeither online or by discrete sampling. In online monitoring, either themass fraction of the polymer formed by the polymerization reaction isdetermined or the liberated enthalpy of reaction of the system as afunction of the monomer mass metered in is determined in a calorimeterserving as reaction vessel. It is also possible to determine theincrease in the polymer content by measuring the speed of sound in thereaction mixture or by monitoring an NIR absorption band characteristicfor the polymer. Alternatively, it is of course also possible to takesamples at certain time intervals and to investigate them with regard totheir polymer content or the content of unconverted starting materials.In certain cases, a decrease in the concentration of a monomer can alsobe directly monitored.

The measurement of the power consumption and of the torque of thestirring member is effected by monitoring and measuring the rotationalspeed and the power consumption of the electrical drive, afterappropriate correction of the frictional losses.

For the power consumption P, there is the following relationship withthe stirring conditions:P=Ne·n ³ ·d ⁵·ρwhere Ne=power characteristic (Newton number), which combines thegeometrical data of the container, of the flow in the container and ofthe viscosity of the product; n=stirrer speed, d=stirrer diameter andρ=density of the reaction mixture. With a knowledge of the powerconsumption P of the reaction mixture, which is distributed in thevolume of the reaction mixture V, an average, effective shear rate τ canbe calculated:τ=C·P/(n·V)in which C is a characteristic constant for the container and thereaction mixture.

Frequently, discrete polymer particles are present, for example in thecase of emulsion polymerization. The progress of the polymerizationmanifests itself here through uniform increase in the polymer particlesize, which increase can be monitored by measurement of the averagedparticle size of the particles by means of a light scattering probe. Forsome applications and products, it is important also to monitor themolecular weight distribution in addition to the conversion of thereaction. This is effected by discrete sampling and measurement in a GPCunit. By automated sampling of the reaction batch and direct applicationto appropriate GPC columns, it is possible to detect the molecularweight distribution more or less in real time. With the aid of thesampling technique, it is also possible easily to monitor the surfacetension of aqueous systems as a function of time.

With the knowledge of the viscosity variation of the liquid phase, themixing times which are important for industrial reaction containers canalso be determined either by tracer methods, for example bydecolorization reactions, or by addition of a reacting substance andmonitoring of the decrease in the concentration thereof—or, in the caseof the addition of an inert component—the rate of the concentrationhomogenization thereof. If, for example, the mixing in of an inertadditive metered from above becomes more difficult with increasingreaction viscosity, a mixing time can be determined from itsconcentration curve of an NIR probe mounted on the reactor bottom. Forsimple model calculations, the person skilled in the art finds in theliterature (e.g. Ullmann's Enzyklopädie der technischen Chemie, 4thedition, 3rd volume, page 259 et seq.) idealized relationships whichpermit an estimation of the mixing time θ:nθ=f(Re) and Re=nd ²·ρ/η

Here, the mixing time is a function of the Reynolds' number Re, which iscomposed of the rotation speed n, the stirrer diameter d and the densityand viscosity of the reaction medium.

The degree of dispersing can be measured in an analogous manner by meansof a light scattering device. As a result of increasing dispersion owingto a shear energy introduced, the mean particle size in the case ofsolids or the drop size in the case of liquid phase which is immisciblewith the solvent (e.g. in an emulsion) decreases, which can be measuredby the time-averaged particle size.

The heat transfer coefficient or heat transition coefficient describesthe quality with which heat of reaction can be removed from the interiorof a reactor to the environment or the cooling medium. It depends bothon the geometrical data and on material, coolant and product properties,which are sufficiently well known to the person skilled in the art. Thedecrease in this value is generally strived for because it is possiblewhereby to cool the reaction mixture more effectively. The definition ofthe heat transition coefficient k isheat of reaction=k·heat-exchange area·temperature differenceif it is assumed that the total heat of reaction must pass through thereactor wall, which represents the heat-exchange area, and a temperaturedifference exists between the reactor content and the cooling medium.

The heat transfer coefficient can be determined and monitored in aparticularly simple manner by measurement in a calorimeter device. Here,the proportion of monomers which was metered into the reaction vessel isknown, and hence the maximum enthalpy of reaction which is to beexpected. By measuring the enthalpy of reaction which is actuallyremoved via cooling, the conversion of the reaction can be determined atany time during the reaction. The very important question in emulsionpolymerization regarding the average number of active centers n in apolymer particle, which control the average reaction rate and thereforealso the rate of enthalpy of reaction, the copolymerization behavior andthe degree of branching, is experimentally accessible via a so-calledbypass measurement. Here, a small stream is pumped from the reactionvessel via a pump through a measuring cell suitable for the measurement.For example, the magnetization of a sample can be determined in ameasuring head of an ESR device. According to this technique, otherspectroscopic measurements or light scattering experiments can also becarried out.

Instabilities in colloidal systems are frequently distinguished in thatcoagulation of particles occurs. The diameter of this particle increasesthereby and this can be monitored by measurement. Depending on the sizeof the particles, the terms microcoagulum or fine coagulum, specks, gritor coarse coagulum are used; all these phenomena are undesired sincethey reduce the quality of the end product, may have to be removed withconsiderable effort or accumulate as deposits in the polymerizationcontainer and must then be removed in an extensive manner by cleaning.Moreover, there is the danger that, although the products can beprepared, they have insufficient stability under the conditions of theapplication. As a rule, the instabilities increase with increasingtemperature.

Yet further measured quantities which can be used for monitoring thereaction are, of course, known to the person skilled in the art. Theinvention relates to the use of the known methods for detecting criticaltime windows, which are then used to make the polymerization processsafer or to obtain the product in better quality.

The invention furthermore relates to some measuring arrangements,devices and methods by means of which time windows can be investigatedin order to detect deviations from the normal course of thepolymerization reaction.

Suitable containers for the preparation of the polymers are sufficientlywell known to the person skilled in the art from the prior art, e.g. J.R. Richards, Computers and Chemical Eng. 30 (2006) 1447-1463 andUllmann's Encyclopedia of Industrial Chemistry, 4th Ed., Vol. 3, pp.505-510. Frequently, internals, e.g. baffles, are also present. As arule, the metallic wall materials of the container, of the stirrer andof the internals are either electropolished or provided with a suitablecoating.

Stirrer designs and process-relevant description of the stirringoperation are known to the person skilled in the art from a multiplicityof publications (for example, Winnacker, Chem. Technologie, 4th edition,vol. 6, page 336, Munich 1982; Ullmann's Enzyklopädie der technischenChemie, 4th edition, vol. 2, page 259, Weinheim). Compared with standardstirring processes, for example the preparation and homogenization ofsolutions, additional difficulties occur in polymer preparation. One ofthe greatest problems here is ensuring as uniform stirring as possiblein the total reaction mixture so that firstly no stationary zones with alarge monomer excess and secondly no zones with high shearing can form.The continuously changing composition of the reaction mixture and theassociated transport reactions of the monomers, assistants and heat ofreaction set constantly changing requirements with regard to thestirring system, in particular in stirred tanks in which differentproducts are produced, optionally even by different polymerizationreactions.

One of the objects is to provide a method in which, during thepreparation process, in the region of critical time windows, suitableprocess quantities are changed so as to obtain the product in conformitywith the process and in conformity with quality requirements.

Time window is understood as meaning a time-limited period during thepreparation process, in particular, but not exclusively, during theactual polymerization. Depending on duration and the rate of thereaction, this may be from minutes up to about 2 hours, as a rule from 1to about 30% of the actual reaction time. Critical time window is to beunderstood as meaning the time in which the process (or the productproperties) deviates or threatens to deviate from its optimallyprescribed reaction path, i.e. path in conformity with the process, andrequires a corrective measure. A plurality of time windows whichoptionally depend on different process qualities and optionally alsooverlap may also exist. The term chronological changes of the processwindow is used if, in this time window, one or more process parameterschange, for example the temperature of the reaction mixture increases ina heating phase.

For determining the critical time window in which microcoagulum and/orshear coagulum is produced by a shear load in a polymerization process,it is possible to use different methods which are based on subjectingthe reaction mixture or part thereof to a shear load at different timesduring the polymerization process and investigating the effect of theload on the fine coagulum content by a suitable method. Shear loadingcan be effected both directly in the polymerization reactor and on aportion of the reaction mixture which is removed continuously (bypassline) or batchwise (sampling). A certain shear load can be achieved indifferent ways known to the person skilled in the art; these include,for example, stirring in the reactor or in an external arrangement,pumped circulation, forcing through a capillary or other constrictionwhich makes it possible to achieve a high shear load. The suitablemethods for detecting or quantitatively determining the coagulum in thedispersion are also known to the person skilled in the art. Theseinclude, for example, particle counters described (Coulter counter),measurement of the pressure increase on filtration of the loadeddispersion through a suitable filter, measurement of the pressureincrease on forcing the dispersion through a capillary, measurement ofthe light scattering of the product before and after the shear loadingor filtration and weighing of the coagulum, etc.

Preferred embodiments of the method for determining critical timewindows will now be described:

Suitable measuring devices in a certain arrangement on thepolymerization container have proven useful for determining timewindows. A particle counter (Coulter counter) which detects particles inthe μm range according to the Coulter principle is used in particularfor cell culture determination but can be used in the area of polymerdispersions in order to detect incipient coagulation when largerparticles, which are designated as microcoagulum or specks by the personskilled in the art, form from normal dispersion particles byagglomeration. Such impurities in the end product are undesired sincethey are evidence of a reduction in the quality of the end product andas a rule cannot be removed or can be removed by filtration only withvery great effort and time requirement. For applications, for example,in unpigmented clear coats, microcoagulum is even absolutely undesired.

By means of a semiautomatic arrangement, a sample, diluted online withan electrolyte suitable for the measurement, can be pumped from thereacting system through the measuring arrangement, which detects thenumber of particles found per unit time. Depending on the software, itmay also be possible to calculate an averaged distribution.

By varying the parameters during the preparation, for example, theincrease of particles having a size of 2 μm as a function of time ismonitored. In addition to the reaction temperature, feed time andconcentrations, influencing variables due to the chosen composition,such as pH, for example due to amounts of bases or buffers metered in,or emulsifier concentrations, solids content, viscosity, amount ofinitiator or the polymer polarity, also serve as possible variables forcontrolling the process. It is sufficiently well known for the personskilled in the art that all these parameters have influence on thestability of the product, associated in each case with correspondingdisadvantages. For example, too high a pH or too high a polymertemperature leads to increased hydrolysis of the monomers or polymersand hence to an increase in the volatile odor substances while anincrease in the emulsifier concentration leads to increased foamformation tendency.

In the case of transparent polymer solutions, the bypass described canbe used for passing the reaction mixture through a continuous measuringcell by means of which an IR or UV absorption measurement or arheological measurement is effected. If an inert material which hassuitable absorption bands in the spectrum is added to the reactionmixture at a certain time during the preparation as trace marking at apoint of the reactor, homogenization can be monitored spectroscopicallyin the bypass. This makes it possible to draw conclusions about themixing time, depending, for example, on stirring conditions, such aspower consumption, or on the instantaneous viscosity of the mixture. Themarking can also be carried out several times in succession or can bemonitored by various inert substances.

For determining the shear load, a small container in which a suitablyshaped stirrer is present is installed in the bypass line of thepolymerization container. This shape can be arbitrarily chosen. However,advantages have been found if the wall spacing is chosen to be small,about 1 mm, and the stirrer blade extends over the entire volume of thecontainer. The stirrer motor can produce very high rotational speeds (upto 10 000 rpm) and is continuously controllable. Present immediatelyafter this stirring cell is a filter cell comprising a 2 μm filter whichfilters the bypass mixture continuously. Pressure transducers whichregister a pressure increase in the line as a result of an increase inthe filter occupancy are present in the bypass cycle. During the entirepolymerization time, hot reaction medium flows through the bypass line,the stirrer cell and the filter cell. For increasing the stirrer speed,a very high shear load which leads to the formation of coagulum can beexerted on the instantaneous reaction mixture. The deposition ofcoagulum on the filter surface then increases the pressure difference atthe filter. The magnitude of the pressure difference reflects the filteroccupancy and hence the sensitivity of the reaction mixture to shearing.Of course, the measurement of the increase in size of the particles orof the microcoagulum, optionally after dilution, can be effected by anoptical method, for example by light scattering, or by anelectrochemical method, for example by Coulter measurement. The spatialseparation of polymerization, shearing and coagulum removal preventsshear coagulum which has formed being recycled into the reactor, whilecomparable conditions can always be established in the reactor for thepreparation of the product. An extension of the bypass line to a secondmeasuring device gives further measured data; expediently, the extensioncan be switched on separately by valves at a suitable time.

If the shear load is changed periodically in the course of thepreparation process, the sensitivity of the reaction mixture to shearingcan be sampled as a function of the reaction time. The simple case,namely flow through the cells stirred at constant speed, also directlygives the time window in which the reaction mixture is unstable underthe applied shear stress.

The occurrence of critical time windows can frequently easily beinterpreted with a knowledge of the ongoing process, although thechemical-kinetic, physical and process-related relationships in theemulsion polymerization are very complex. It should be noted, forexample, that the particles increase in size as a result of thepolymerization process under polymerization conditions in which thetotal particle count remains constant. According to the increase insize, the total surface area of the particles on which the stabilizingemulsifier molecules are present in absorbed form increases. If theincrease in the surface area of the polymeric phase takes place morerapidly than the rate of addition of the stabilizing emulsifiers, thecolloidal stability of the system generally decreases. The influence ofthe pH and of the viscosity can also be explained in a comparablemanner. The cooperation of these influences gives rise, during thepreparation process, to very specific phases (critical time windows)having particularly high sensitivity, during which counteraction may benecessary. Depending on the cause of the reduced stability, suchmeasures may be briefly adapted stirrer speed changes, the change in themonomer metering rate and hence in the generation of heat of reaction, apH change, increased emulsifier metering, dilution by solvent addition,a change in the reaction temperature, viscosity regulation, changedinitiator metering or adaptation of the pressure conditions (in the caseof reactions under pressure).

The invention also comprises a computer program comprising program codewhich is suitable for carrying out a method according to the inventionif the computer program runs on a suitable computing or control device.

Of course, the abovementioned features and the features still to beexplained below can be used not only in the respective statedcombination but also in other combinations or alone without departingfrom the scope of the present invention.

The invention is illustrated below on the basis of some working exampleswith reference to the figures.

FIG. 1 shows a graph of the results of the measurement of the coagulumformation from an experimental example 5, the amount of coarse particlesbeing plotted in relative units against the reaction time.

FIG. 2 shows a schematic diagram of a measurement arrangement accordingto the invention comprising a rheological cell.

EXAMPLES Example 1a

A mixture of 5.5 kg of water, 0.52 kg of emulsifier 1 and 125 g ofitaconic acid is initially taken under nitrogen in a 40 l reactorequipped with an MIG stirrer and is heated to 95° C. after addition of5% of feed 1 at 140 rpm. After addition of 0.60 kg of a 5% strengthsolution of sodium peroxodisulfate, the remainder of feed 1 is meteredin after 10 min and, simultaneously therewith, a solution of 2.25 kg ofa 4.4% strength sodium peroxodisulfate solution is metered in 4 h. Aftera further 2 h at 90° C., treatment is effected with a solution of 0.9 kgof a 2% strength solution of tert-butyl hydroperoxide and 0.95 kg of adilute, aqueous solution of 66 g of sodium hydrogen sulfite (40%strength) and 5 g of acetone in 2 h and thereafter cooling to 50° C. iseffected and a pH of about 5.5 is slowly established with sodiumhydroxide solution. After addition of customary amounts of antifoam andbactericide, unconverted monomer is removed with steam over the courseof 5 h. A 47% strength, coagulum-free dispersion, pH about 5.7, particlesize 82 nm (light scattering) and a glass transition temperature ofabout 4° C., is obtained. The viscosity was determined as 150 mPa·s(Brookfield, RV, spindle 2, 100 rpm, 25° C.). 50 ppm of styrene and 20ppm of phenylcyclohexene (PCH) were found by gas chromatography, but nobutadiene and acrylonitrile.

Composition of Feed 1 (Metered Simultaneously from DifferentContainers):

6.2 kg of water

0.3 kg of 30% strength solution of a sulfated C12 fatty alcoholethoxylate (3 EO) (emulsifier 1)

0.27 kg of sodium hydroxide solution (25% strength)

0.6 kg of acrylic acid

7.2 kg of styrene

0.8 kg of acrylonitrile

0.45 kg of acrylamide (50% strength)

6.0 kg of butadiene

0.45 kg of chain-transfer agent

0.5 kg of water for flushing the pipes

Examples 1b-e

Example 1a was reproduced and the speed during the reaction was changedaccording to the following data:

b) stirring for 180 min at 90 rpm, 180 min at 140 rpm

c) stirring for 15 min at 90 rpm, 345 min at 140 rpm

d) stirring for 15 min at 140 rpm, 345 min at 90 rpm

e) permanent speed change between 140 and 90 rpm (in each case 10 mindecrease then 10 min increase)

Example 1f

The coagulum contents of the products 1a-e produced are summarized inthe following table. The tendency to foam formation during the reactionas well as in the finished product did not differ. The physical data ofthe products do not differ in the accuracy of the measurement from thoseof example 1a.

The coagulum values (cf. tab. 1) were obtained by sieve fractionationover a 4-fold screen by diluting 1.0 kg of dispersion with 1.0 kg ofwater and allowing it to run through the filter combination for 1 min.After drying (120° C.), the proportion of coagulum was determinedgravimetrically.

TABLE 1 Coagulum contents in mg/kg dispersion Screen A B C D E 25 μm 36058 49 61 55 45 μm 7 16 29 65 44 85 μm 11 8 13 25 15 125 μm  59 28 12 4624 Total 437 110 103 197 138

It was found that the coagulum formation can be effectively reduced byreducing the stirrer speed in the first quarter hour of the reaction.The first 15 min are the critical time window for this product withregard to coagulum formation.

Example 2a

A bimodal polymer dispersion is prepared on the production scale. Aninitially taken mixture comprising 0.4 part of ascorbic acid in 86.6parts of water is heated to 90° C. under nitrogen and stirred with amulti-speed stirrer at an external paddle speed of about 5 m/s. At 90°C., 14 parts of 5% strength sodium peroxo-disulfate solution are addedand metering in of an emulsion according to feed 1 is begun. Theaddition is effected with the proviso that it is increased in the courseof about 1 h slowly from an initial amount linearly in two stages to amaximum value (4 times the amount of the starting value) (time window1), but is carried out in such a way that the complete cooling capacityof the reactor is utilized toward the end of the addition. For thispurpose, a time of about 5.0 h is required for metering in the monomeremulsion. In this time, a further 39 parts of sodium peroxodisulfatesolution are simultaneously metered in, and washing with 8 parts ofwater is effected.

The emulsion consists of

Water 161 parts, 2-Ethylhexyl acrylate 580 parts, Methyl methacrylate 51parts, Vinyl acetate 27 parts, Acrylic acid 3 parts,and 5.0 parts of emulsifier 2 and 6.0 parts of emulsifier 3, 5.0 partsof sodium hydroxide solution (25% strength) and a further 15 parts of acopolymerizable monomer. These components are added in stages in somecases.

Emulsifier 2 is a 45% strength solution of a neutralizedbisalkyldiphenyl oxide disulfonate and emulsifier 3 is a sodium salt ofa C12 fatty alcohol ether sulfate having about 30 mol of EO (calculatedon the basis of 100%).

In the further, subsequent process steps, a further 29 parts ofdifferent raw materials are added so that a 65% strength by weightdispersion is present at the end. The dispersion is obtained in acoagulum-free form on filtration and has a pH of 4.7 and a viscosity ofabout 450 mPa·s (rotational viscometer at 100/sec).

Example 2b

Method 2a) is reproduced in the same reaction container. After anemulsion metering time of about 70 min (i.e. 10 min after time window1), the speed of the stirrer is increased by 14% (time window 2). Withfurther utilization of the maximum cooling power of the reactor, theemulsion metering time can now be shortened by 40 min or reduced by 13%.An improvement in the heat removal is achieved, and the measuredphysical quantities of the dispersion, including the particle sizedistribution and the performance characteristics, are identical withinthe tolerances of the measurement.

2c) Comparative Experiment

Comparative method 2a is reproduced in the same reaction container withthe difference that an emulsion metering rate (maximum value) constantover the metering time is established, i.e., the metering rate in timewindow 1 is constant and is also maintained after time window 1. Thestirrer speed is likewise left constant (constant stirrer speed in timewindow 2). The metering is effected with utilization of the maximumcooling capacity in a metering time of 4.5 h. During the preparation,the dispersion thickened.

By comparison of 2c with 2a, it is found that the first 60 min of thepolymerization represent the critical time window 1 with regard toviscosity. Comparison of 2b with 2a shows that the optimization of thestirring conditions in time window 2 makes it possible further to reducethe metering time, which is limited by the heat removal.

Example 3a

An initially taken mixture consisting of 2.0 kg of water, and 0.2 kg ofa 20% strength by weight seed latex is initially taken under nitrogen ina pressurized reactor having a capacity of 200 l and is heated. At aninternal temperature of 75° C., 0.33 kg of feed 2 is added and heated to80° C. in 1 h (time window 1). Thereafter, feed 1 and feed 2 are startedand are added in 6.0 h. After the end of the feeds, the container iswashed with 0.25 kg of water and the reactor content is heated to 85° C.for complete polymerization. After stirring for 1 h, cooling to 60° C.is effected and in each case a solution of 34.0 g of tert-butylhydroperoxide (70% strength) in 0.20 kg of water and a solution of 21.0g of sodium disulfite in 0.25 kg of water are added simultaneously inthe course of 2 h. After stirring for a further hour, cooling iseffected and neutralization is effected with 0.24 kg of a 25% strengthby weight sodium hydroxide solution in 30 min and 20 g of an antifoamand 50 g of a customary, aqueous bactericide are added. The product isobtained in coagulum- and speck-free form, has a pH of 6.7, a dry valueof 48.3% and a light transmittance (0.01% strength, 1 cm layerthickness, photometer) of 77% and can be easily filtered. A 1 kg sampleis filtered through a 45 μm fine screen and leaves behind <0.01% ofcoagulum.

Composition of Feed 1:

Water 4.40 kg Sodium pyrophosphate 40 g Emulsifier 2 50 g Sodium laurylsulfate (15%) 104 g Sodium hydroxide solution (25%) 0.18 kg Acrylic acid0.25 kg Styrene 1.36 kg Acrylonitrile 2.00 kg n-Butyl acrylate 4.40 kg

Feed 2 is a solution of 46 g of sodium peroxodisulfate in 0.62 kg ofwater.

Example 3b

Experiment 3a) is repeated with the following difference:

The batch is prepared in a 1 m³ pressurized reactor and 5 times thestated amounts are used. The addition of feeds 1 and 2 is begun at aninternal temperature of 85° C., the reactor content is further heated in15 min (time window 1) and feeds 1 and 2 are then metered in at aninternal temperature of 100° C. in 3.0 h. After complete addition,stirring is effected for 1 h at 100° C., then cooling to 60° C. iseffected and the procedure is continued in a corresponding manner.

The product is obtained in coagulum- and speck-free form, has a pH of7.0, a dry value of 49.8% and a light transmittance of 64% and can beeasily filtered. A 1 kg sample is filtered through a 45 μm fine sieveand leaves behind 0.013% of coagulum.

Example 3c

Experiment 3a) is repeated with the following difference: the additionof feeds 1 and 2 is begun at an internal temperature of 95° C., thereactor content is further heated in 15 min (time window 1) and feeds 1and 2 are then metered in at an internal temperature of 110° C. in 2.0h. After complete addition, stirring is effected for 1 h at 110° C.,then cooling to 60° C. is effected and the procedure is continued in acorresponding manner.

The product is obtained in coagulum- and speck-free form, has a pH of6.9, a dry value of 49.9% and an LT value of 68% and can be easilyfiltered. A 1 kg sample is filtered through a 45 μm fine sieve andleaves behind <0.010% of coagulum.

Example 3d

Experiment 3a) is repeated with the following difference: the additionof feeds 1 and 2 is begun at an internal temperature of 95° C., thereactor content is further heated in 15 min (time window 1) and feeds 1and 2 are then metered in at an internal temperature of 120° C. in 3.0h. After complete addition, stirring is effected for 1 h at 120° C.,then cooling to 60° C. is effected and the procedure is continued in acorresponding manner.

The product is obtained in coagulum- and speck-free form, has a pH of6.9, a dry value of 49.9% and an LT value of 68% and can be easilyfiltered. A 1 kg sample is filtered through a 45 μm fine sieve andleaves behind <0.010% of coagulum.

Example 3e

Example 3d is repeated with the following change: the addition of feed 1and feed 2 is carried out under pressure at an internal temperature of120° C. (time window 1=0 min). The metering is effected in 3 h.Thereafter, the procedure is continued analogously to example 3a. Theproduct is obtained with a low coagulum and speck content, has a pH of6.5, a dry value of 49.3% and an LT value of 62% and can be easilyfiltered. The filtration test (45 μm screen) gives a coagulum value of0.3% which is no longer tolerable. A molecular weight determinationgives a lower molecular weight than the products from examples 3a-3d.

By comparison of examples 3a to 3e, it is found that the first reactionphase (time window 1) is critical with regard to the process variable oftemperature and the coagulum content. Outside the time window, thehigher temperature can be used for improving the cooling performance,which is reflected in a shorter metering time.

Example 4

The products from examples 3a, 3c and 3d were tested against acorresponding production material as a binder for paper coating slips.In addition to the proportion of coagulum, the product from example 3eproves to be unsuitable with regard to mechanical stability (stirringfor 10 min with Ultraturrax stirrer at 5000 rpm, which represents apreliminary test) and viscosity and was not included in the testing.

TABLE 2 Formulation (all data in % by weight) 4a 4b 4c 4d Hydrocarb 90¹⁾ 70 70 70 70 Amazon 88 ²⁾ 30 30 30 30 Polysalz S ³⁾ 0.4 0.4 0.4 0.4Sodium hydroxide solution 0.05 0.05 0.05 0.05 25% strength CMC 7L2T ¹⁾0.5 0.5 0.5 0.5 Reference 10 Proportion of 3a 10 Proportion of 3c 10Proportion of 3d 10 ¹⁾ Commercial product of Omya, Cologne, Germany; ²⁾Commercial product of Kaolin International B.V. Antwerp, TheNetherlands; ³⁾ Commercial product of BASF AG, Ludwigshafen, Germany.

TABLE 3 Test results Machine coating 10 g/m² on Scheufelen paper 4a 4b4c 4d pH 8.5 8.5 8.7 8.5 Viscosity 20 rpm mPa · s: 850 850 850 1025(Brookfield) 100 rpm mPa · s: 270 270 270 320 Pick resistance NA cm/s124 119 122 120 IGT dry PA cm/s 266 253 271 300 Pick resistance 0.6 m/:% 60.9 53.6 53.6 50.0 IGT wet Solid area(D) = D: 1.48 1.30 1.3 1.21 2.43Offset test >6 >6 >6 >6

Example 5a Determination of a Critical Time Window in the Preparation ofa Dispersion in an Experimental Laboratory Apparatus with ParticleMeasurement

A dispersion is prepared according to the following general method in a4 l double-jacket glass apparatus having an attached stirrer motor(pilot plant), three separate feeds and an attached reflux condenser.The stirrer used is a three-speed crossbeam stirrer having a d/D ratioof 0.9, which is operated at 150 rpm (1.4 m/s paddle speed).

From a monomer mixture having the composition

50% by weight of n-butyl acrylate,

46% by weight of styrene,

-   -   2% by weight of acrylic acid,    -   2% by weight of methacrylic acid,        an emulsion was prepared using 0.1% by weight of emulsifier 2        and 0.1% by weight of sodium lauryl sulfate (in each case based        on the sum of the monomers) in a container by thorough stirring.        The composition of the emulsion is such that a 50% strength by        weight dispersion is present at the end of the reaction.

0.30 kg of deionized water was initially taken in the reaction vessel, adefined amount of sodium lauryl sulfate was added and heating to 80° C.was effected under nitrogen. The amount of initially taken sodium laurylsulfate is such that the mean particle diameter of the end dispersion isjust 150 nm (light scattering). Alternatively, a corresponding amount ofseed latex can also be used. 2% of the prepared monomer emulsion areadded to the initially taken mixture, and a solution of 0.3% by weightof sodium peroxodisulfate in 200 g of water (=feed 2), a solution of 8.0g of sodium bicarbonate in 200 g of water (=feed 3) and the remainder ofthe emulsion are metered in continuously in 3 h at the definedpolymerization temperature.

Reaction mixture can be removed from the reaction space via a bottomopening and recycled by means of a small peristaltic pump. On thepressure side of the peristaltic pump, however, a small portion isbranched off, thermostatted and diluted in a suitable ratio with anelectrolyte solution and fed semicontinuously to a Coulter counterdevice. The measuring time is about 1 min; the next metering is effectedthereafter.

By varying the composition and the reaction conditions, the occurrenceof microcoagulum can be observed. The measuring arrangement thus permitsthe direct checking of the process quantities for determining criticaltime windows.

Example 5b

As in example 5a, but without sodium bicarbonate in feed 3.

Example 5c

As in example 5b, but at 95° C. polymerization temperature.

Example 5d

As in example 5a, with the difference that, after a feed time of 60 min(time window 1), the reaction temperature is slowly increased to 95° C.in 15 min and the stirrer speed is also increased during this procedureto 200 rpm (time window 2).

The results of the measurement are reproduced in FIG. 1. The omission ofan assistant (sodium bicarbonate, example 5b compared with example 5a)shows the formation of microcoagulum during the entire reaction and inexample 5c in the critical time window of 60 min by an increase in therelative units of the measured signal. At lower reaction temperature intime window 1 and in the presence of the assistant, no formation of themicrocoagulum is observed, even if the shear load is increased byincreasing the stirrer speed in time window 2. Time windows 1 and 2relate to different process variables and do not overlap.

Example 6 Determination of a Critical Time Window in the Preparation ofa Dispersion in an Experimental Laboratory Apparatus by Means of a ShearCell

Example 5b is repeated. A peristaltic pump 20 (delivery of not more than120 ml/min) which pumps the reaction mixture at 25 ml/min through arheological cell 14 is present in the bypass line (cf. FIG. 2). The cell14, in which a cylindrical rotor driven by a motor M rotates in acontrollable manner up to 10 000 rpm, has a volume of 25 ml. Behind thecell 14, a planar filter 18 having a pore diameter of 2 μm is installedin the pumped circulation. The filter occupancy is determined bymeasuring the pressure difference by means of pressure transducers 16before and after the filter 18 and is registered in a computer or acontrol device (not shown) as a function of the reaction time during themeasurement (=increase in the rotational speed in the cell). Thefiltrate is recycled in thermally insulated lines into the reactioncontainer 12.

Five min after the start of the polymerization, the speed program forthe measurement in the shear cell 14 is started for the first time. Fromthe rest speed (50 rpm), the speed is increased to 3000 rpm within 40sec, maintained for 20 sec and reduced again to 50 rpm in 20 sec. Thepressure of the two load cells 16 and the corresponding pressuredifference and the temperature of the medium are registeredcontinuously. The instantaneous solids content in the reactor 12 isdetermined computationally from the metering time and the metering rateand the composition of the monomer emulsion. At a pressure difference of150 mbar, the filter is fully occupied.

Metering time Solids Pressure difference [min] [%] [mbar] 0 11 0 6 19 216 28 2 26 33 2 36 37 3 46 39 3 56 41 3 66 43 3 76 44 3 86 45 4 96 46 14106 47 26 116 47 45 126 48 80 136 48 150 146 49 150 156 49 150 166 49150 176 50 150 180 50 150

The apparatus shows the increase in deposited fine coagulum, beginningafter a reaction time of about 85 min. In this case, the critical timewindow is to be regarded as being from a reaction time of about 80 min.

1. A method for carrying out a polymerization process in a stirredreactor, comprising: (i) determining at least one critical time window,wherein the critical time window is at least one time interval withinthe polymerization process during which the process shows an actual oran expected divergence from a designated optimal reaction path of thepolymerization process, by monitoring at least one polymerizationprocess parameter and an associated range (a “process window”), in whicha reaction product is obtained which meets requirements, as a functionof reaction time; and (ii) adapting one or more process conditionsduring the critical time window, in order to maintain the polymerizationprocess parameter within the process window, wherein the adapting (ii)is effected by controlling flow behavior by changing stirrer speed in astirred reactor.
 2. The method according to claim 1, wherein thedetermining of the critical time window (i) is effected by comparison ofa detected value for the at least one polymerization process parameterwith the process window.
 3. The method according to claim 1, wherein theprocess window varies over time.
 4. The method according to claim 1,wherein the at least one polymerization process parameter is the heattransfer coefficient.
 5. The method according to claim 1, wherein the atleast one polymerization process parameter is the mixing time.
 6. Themethod according to claim 1, wherein the at least one polymerizationprocess parameter is the shear stress.
 7. The method according to claim1, wherein the at least one polymerization process parameter is thespecific power input.
 8. The method according to claim 1, wherein thepolymerization process is an emulsion polymerization process.
 9. Themethod according to claim 1, wherein the polymerization process is asuspension polymerization process.
 10. A method for determining a timeinterval within a polymerization process in a reaction container,wherein a microcoagulum is formed, comprising: (i) continuously removingof a portion of a reaction mixture from the reaction container by pumpcirculation via a bypass comprising a mean particle size increasemeasuring arrangement; (ii) determining an increase in particle size inthe portion of the reaction mixture; and (iii) optionally, recycling theportion into the reaction container, wherein the time interval ispresent when a measured particle size exceeds at least 1.5 times anexpected statistical mean particle size of an end product.
 11. A methodfor determining a time interval within a polymerization process in areaction container, wherein a microcoagulum and/or shear coagulum isproduced by shear load in the polymerization process, comprising: (i)continuously removing of a portion of a reaction mixture from thereaction container by pump circulation via a bypass comprising ahigh-speed stirrer producing a shear field in a circulating product; and(ii) detecting polymer particles in the portion by filtration and/ordetecting an increase of microcoagulum optically and/or electrically;and (iii) optionally, recycling the portion into the reaction container.12. A non-transitory computer-readable storage medium with acomputer-executable program stored thereon, wherein the programinstructs a microprocessor of the computer to execute a method whichdetermines at least one time interval within a polymerization process ina reaction container, wherein a microcoagulum is formed, wherein aportion of the reaction mixture is continuously removed from thereaction container by pump circulation via a bypass comprising a meanparticle size increase measuring arrangement, and, optionally, theportion is recycled into the reaction container wherein the timeinterval is present when the measured particle size exceeds at least 1.5times the expected statistical mean particle size of an end product. 13.A non-transitory computer-readable storage medium with acomputer-executable program stored thereon, wherein the programinstructs a microprocessor of the computer to execute a method whichdetermines a time interval within a polymerization process in a reactioncontainer, wherein mixing processes occur during the polymerizationprocess and the mixing processes may change in a disadvantageous manneras a result of reaction progress and/or as a result of a change inprocess parameters, wherein a suitable tracer is added to a reactionmixture; and homogenization of the reaction mixture is spectroscopicallyor electrochemically monitored in the reaction container or in a bypassline.
 14. A non-transitory computer-readable storage medium with acomputer-executable program stored thereon, wherein the programinstructs a microprocessor of the computer to execute a method whichdetermines a time interval within a polymerization process in a reactioncontainer, wherein a microcoagulum and/or shear coagulum is produced byshear load in the polymerization process, wherein a portion of areaction mixture is continuously removed from the reaction container bypump circulation via a bypass comprising a high speed stirrer producinga shear field in a circulating product, and an increase of microcoagulumis detected by filtration of polymer particles and/or optically and/orelectrically, wherein, optionally, the portion is recycled into thereaction container.
 15. The method according to claim 10, comprisingrecycling the portion into the reaction container.
 16. The methodaccording to claim 11, comprising recycling the portion into thereaction container.
 17. The method according to claim 11, wherein thedetecting comprises the filtration.
 18. The method according to claim11, wherein the detecting comprises detecting an increase ofmicrocoagulum optically.
 19. The method according to claim 11, whereinthe detecting comprises detecting an increase of microcoagulumelectrically.
 20. The method according to claim 11, wherein thedetecting comprises detecting an increase of microcoagulum optically andelectrically.
 21. The method according to claim 11, wherein thedetecting comprises the filtration and detecting an increase ofmicrocoagulum optically.
 22. The method according to claim 11, whereinthe detecting comprises the filtration and detecting an increase ofmicrocoagulum electrically.
 23. The method according to claim 11,wherein the detecting comprises the filtration and detecting an increaseof microcoagulum optically and electrically.